Mechanical Engineering Commons^™

Note On The Rate And Energy Efficiency Limits For Additive Manufacturing, Timothy Gutowski, Sheng Jiang, Daniel Cooper, Gero Corman, Michael Hausmann, Jan-Anders Manson, Timo Schudeleit, Konrad Wegener, Matias Sabelle, Jorge Ramos-Grez, Dusan P. Sekulic

Mechanical Engineering Faculty Publications

We review the process rates and energy intensities of various additive processing technologies and focus on recent progress in improving these metrics for laser powder bed fusion processing of metals, and filament and pellet extrusion processing of polymers and composites. Over the last decade, observed progress in raw build rates has been quite substantial, with laser metal processes improving by about 1 order of magnitude, and polymer extrusion processes by more than 2 orders of magnitude. We develop simple heat transfer models that explain these improvements, point to other possible strategies for improvement, and highlight rate limits. We observe a …

Considering Manufacturing In The Design Of Thick-Panel Origami Mechanisms, Erica Brunson Crampton

Theses and Dissertations

Origami has been investigated and demonstrated for engineering applications in recent years. Many techniques for accommodating the thickness of most engineering materials have been developed. In this work, tables comparing performance and manufacturing characteristics are presented. These tables can serve as useful design tools for engineers when selecting an appropriate thickness-accommodation technique for their application. The use of bent sheet metal for panels in thick-origami mechanisms shows promise as a panel design approach that mitigates several trade-offs between performance and manufacturing characteristics. A process is described and demonstrated that can be employed to use sheet metal in designs of origami-adapted …

Hysteresis Heating Of Railroad Bearing Thermoplastic Elastomer Suspension Element, Oscar O. Rodriguez, Arturo A. Fuentes, Constantine Tarawneh, Robert E. Jones

Mechanical Engineering Faculty Publications and Presentations

Thermoplastic elastomers (TPE’s) are increasingly being used in rail service in load damping applications. They are superior to traditional elastomers primarily in their ease of fabrication. Like traditional elastomers they offer benefits including reduction in noise emissions and improved wear resistance in metal components that are in contact with such parts in the railcar suspension system. However, viscoelastic materials, such as the railroad bearing thermoplastic elastomer suspension element (or elastomeric pad), are known to develop self-heating (hysteresis) under cyclic loading, which can lead to undesirable consequences. Quantifying the hysteresis heating of the pad during operation is therefore essential to predict …

Open Source Multi-Head 3d Printer For Polymer-Metal Composite Component Manufacturing, J. Laureto, Joshua M. Pearce

Department of Materials Science and Engineering Publications

As low-cost desktop 3D printing is now dominated by free and open source self-replicating rapid prototype (RepRap) derivatives, there is an intense interest in extending the scope of potential applications to manufacturing. This study describes a manufacturing technology that enables a constrained set of polymer-metal composite components. This paper provides (1) free and open source hardware and (2) software for printing systems that achieves metal wire embedment into a polymer matrix 3D-printed part via a novel weaving and wrapping method using (3) OpenSCAD and parametric coding for customized g-code commands. Composite parts are evaluated from the technical viability of manufacturing …

Additive Manufacturing For Post-Processing, Nathan D. Goodwin, Andrew Furmidge

Mechanical Engineering

Additive Manufacturing for Post Processing (AMPP) is a team comprised of two Cal Poly Mechanical Engineering students: Nathan Goodwin and Andrew Furmidge. The project is focused in the area of metal additive manufacturing (AM) machines, which are still a developing technology. Improvements have been made to the quality of the machines in the past years, but many limitations still exist. One of these is the inability to print parts that are larger than the build volume. In an effort to solve this problem, whole parts are divided into pieces that are printed individually. This team’s senior project is to create …

The Development Of A Vacuum Forming System For Kydex® And Other Thermoplastic Sheet, Andrew G. Smith

Electronic Theses and Dissertations

Vacuum forming is a popular, cost effective method amongst large and small scale applications. The method is used to mold a material to the surface of a mold/pattern in order to create a negative copy for reproduction or an object in positive form. The prototype vacuum forming system developed and documented herein is of a membrane-seal type that consists of three (3) principle parts: radial platen, Hinged Frame and Platen Support Assembly, and a PVC surge tank. Each part is described in detail through design, manufacturing, and testing processes. The design supports functional versatility, small scale molding, and uses readily …

Sae Baja - Front Suspension And Steering, Gabriel Brumm, Luke Lambert, John Saliba

Scholar Week 2016 - present

The SAE Baja Front Suspension Senior Design Team has successfully chosen a design alternative to build, test, and possibly revise as this project moves forward. The team learned about the problems that occurred with the steering and suspension systems last year at the SAE Baja competition from Dr. Allen and ONU Baja team members that attended competition last year (which includes senior design team member John Saliba). After understanding the failures that occurred last year, the design team set design goals with a focus on increased durability, increased driver control and vehicle handling, and reduced weight.

A Study Into The Production Efficiency Of Cal Poly Chocolates, Fernando Calderon

Industrial and Manufacturing Engineering

The project objective was to: identify ways to reduce the production cost of Cal Poly Chocolates. The project was executed through the DMAIC approach, a data driven improvement cycle. Using several industrial engineering tools, six improvement opportunities were found. Three project deliverables were created and three process changes were recommended. The total annual savings, if recommendations are implemented, sum to $1700.

High Accessibility Cabinet Insert, Matthew Leal

All Undergraduate Projects

Watching grandparents and parents get older, the struggle of day-to-day activities generally increases. One of the most recurring issues the older generation experiences nearly daily is their inability to reach dishes, glassware, and other things on the topmost shelves of a kitchen. Not only is it difficult for them to use things such as stepstools, it also becomes increasingly dangerous. With age, a fall from any height could be catastrophic. With this scenario in mind, a user-friendly cabinet insert would be a very effective way to combat this issue. However, many existing models of cabinet designed to fit these requirements …

Pin Router Duplicator Base, Matthew Tebo

All Undergraduate Projects

The idea for the following project came from the Lean Manufacturing class that is offered at Central Washington University. In this class the manufacturing processes is demonstrated through the production of guitar kits. A problem with the class is that the CNC machine gets backed up causing a bottleneck in the production line. The solution to this problem was to make a pin router duplicator. A pin router duplicator is a device that allows the operator to trace a finished part with a pin while a router mimics its movements, cutting a new part. The component that is looked into …

Design And Prototype Of Next Generation Nascar Brake Caliper, Jesse Crowder, John Knighton, Lenny Ports, Miranda Snyder

Capstone Design Expo Posters

Efficient braking is pivotal to the success of a NASCAR team. Braking occurs when the brake pedal is depressed, causing hydraulic pressure within the caliper housing and on the pistons, which forces the pistons to push the brake pads against the rotors reducing the vehicle’s speed due to the high friction between the pads and rotors. High performance brake calipers are arguably one of the most crucial components of a race car braking system. Short track brake calipers were designed to efficiently decelerate vehicles traveling upwards of one-hundred twenty miles per hour. This is an essential function of vehicles on …

Automated Din Rail Cut And Punch Machine, Youssif Alkheder, Gaston Charreun, Derrian Flemings, Jonathan Liss

Capstone Design Expo Posters

Our project’s main goal is to optimize the process of punching and cutting DIN rail in a manufacturing setting. The current method for cutting and punching DIN rails is tedious and simply too time consuming. An operator is needed to manually load the DIN rail into the cutter, measure the required length and activate the cutter. While this simple process may not take too long at first glance, companies, like Weidmuller, must be able to produce large-quantity orders to successfully meet the demands of their customers. By turning to automation, we are effectively reducing the amount of time it takes …

Utilizing Reprap Style 3d Printers For The Manufacturing Of Composite Heat Exchangers, John Laureto

Dissertations, Master's Theses and Master's Reports

The low cost 3D printing market is currently dominated by the application of RepRap (self-replicating rapid-prototyper) variants. Presented in this document are practical utilizations of RepRap technology. Developed are innovative processes to manufacture composite materials systems for thermal management solutions.

First, a laser polymer welder system is validated by quantifying maximum peak load and weld width of linear low density polyethylene (LLDPE) lap welds as a function of linear energy density. The development of practical engineering data, in this application, is critical to producing mechanically durable welds. Developed laser and printer parameter sets allow for manufacturing of LLDPE multi-layered heat …

Metal Cutting And Manufacturing Economics Project For Freshmen, Hüseyin Sarper, Nebojsa I. Jaksic, Linda Vahala

Electrical & Computer Engineering Faculty Publications

This paper describes a laboratory experiment and a team project to teach manufacturing concepts to new students. This project is one of two team projects of 1.5 credit portion of a two-credit course in exploration of engineering and technology. This course teaches students skills they need late and teamwork is a major skill that they acquire. They organize into a group with specialized responsibilities for the purpose of calculating the total production time and cost of a manufactured part using turning, drilling, and milling operations. Students also learn or improve spreadsheet skills while performing data entry and necessary machining calculations. …

Wardjet Waterjet Cutting Head Actuator Design, Micah Steiner, Jacob D. Augustynovich, Benjamin Heckert

Williams Honors College, Honors Research Projects

In an effort to increase efficiency and productivity, WARDJet was seeking a better actuation method for the cutting head on their waterjets. Current actuation methods were, for the most part, purely mechanical, relying on compressed air, springs, and water pressure to open and close the valve to 60,000 psi of water. Increasing the speed of the on/off cycle times of the waterjet would allow for faster movements of the cutting head from one cut to the next, increasing the overall amount of products cut in a day, week, and year. This obviously points to increased sales, increased profit, and increased …

Eliminating The Illusion Of Learning From Engineering Courses, Jason Weaver

Faculty Publications

This paper describes the efforts of the author to incorporate tools into an undergraduate engineering course to help facilitate better learning and assess proficiency more effectively by avoiding the illusion of learning. Several techniques are used, including suggestions from the recent book Make It Stick by Brown, Roediger, and McDaniel. Student feedback and instructor observations are discussed, and future recommendations for the course are given